WO2022000237A1 - Composite board substrate, composite board substrate preparation method, and decorative board - Google Patents

Abstract

The present invention relates to a composite board substrate, a composite board substrate preparation method and a decorative board, and is intended to provide a novel substrate with a good flexibility and a high strength. The composite board substrate is prepared from polypropylene fibers, filling fibers, a flame retardant, a coupling agent and an inorganic filler by means of hot pressing, wherein the filling fibers are one or more of PET fibers, PE fibers, glass fibers, carbon fibers and wood fibers. The preparation method involves: firstly mixing the inorganic filler, the filling fibers and the coupling agent; then blending the mixed filler with the polypropylene fibers; next, paving the blended material into a strip shape, then pressing and molding same, and slicing same to obtain material sheets; subsequently laminating multiple layers of the material sheets, then hot-pressing same for 5-30 min at a temperature of 165-250°C and a pressure of 5-20 MPa, and cooling same to obtain a semi-finished substrate; and finally trimming and sanding the semi-finished substrate into a finished substrate. The substrate has the advantages of being stable in size and high in tenoning strength, and can be compounded with a melamine impregnated paper layer, an HPL layer or a PP decorative surface layer to manufacture different decorative boards.

Description

A composite board base material, a method for preparing a composite board base material, and a decorative board technical field

The present application relates to the technical field of composite panels, in particular to a composite panel substrate, a method for preparing a composite panel substrate, and a decorative panel.

Background technique

As the main structural layer of the composite board, the physical and mechanical properties of the substrate are extremely important for the application of the composite board. At present, in the field of composite board production, glass magnesium board substrate is the most common.

For example, Chinese patent CN101871246B discloses a glass magnesium board, which is composed of a molding agent, a reinforcing material, a lightweight filler, a modifier and water. Although it improves the comprehensive performance of the glass magnesium board substrate to a certain extent, it contains The free chloride ions existing in the glass magnesium board substrate of magnesium chloride are difficult to control, which will cause poor water resistance and obvious warpage deformation. At the same time, it is easy to absorb moisture and return to halogen. In a humid environment, water droplets will appear on the surface of the object. In some cases, after getting wet, the object will crack and finally fall off slowly.

In order to solve the above-mentioned technical problems, Chinese invention patent application CN110746174A discloses a class A fireproof mineral board and its preparation method: 2-15 parts of magnesium sulfate and 2-20 parts of water are mixed to make a magnesium sulfate solution, and 10-90 parts of magnesium sulfate are mixed. Parts of plant fibers or granules are mixed with 5-66 parts of magnesium oxide, 0-30 parts of other fillers and 0.1-5 parts of modifiers, and then mixed with magnesium sulfate solution evenly, and then through mold laying, cold pressing and curing. A grade A fireproof mineral board was obtained.

However, the toughness of this kind of mineral plate itself is poor, and it is very easy to crack after bending, and the maximum internal bonding strength of the glass magnesium plate substrate disclosed in the above patent application can only reach 1.5N/mm ² , and the strength still needs to be improved. Therefore, the present application provides a novel substrate with good toughness and high strength.

SUMMARY OF THE INVENTION

In view of the deficiencies in the prior art, one of the purposes of the present application is to provide a composite board substrate, which has the advantages of good toughness and high strength.

The second purpose of the present application is to provide a method for preparing a composite board base material, and the composite board base material prepared by this method has the advantages of good toughness and high strength.

The third purpose of the present application is to provide a decorative board, which has the advantages of good toughness, high strength, and not easy to crack.

The purpose of this application is achieved through the following technical solutions:

A composite board base material is made by hot pressing of the following raw materials by mass percentage,

The filler fiber is a mixture of one or more of PET fiber, PE fiber, glass fiber, carbon fiber and wood fiber.

Compared with the traditional glass magnesium board substrate, the present application does not need to use magnesium oxysulfide gel material, so there is no problem of moisture absorption and halogen return. At the same time, the composite board substrate of the present application is hot-pressed with polypropylene fibers and filler fibers (the filler fibers are a mixture of one or more of PET fibers, PE fibers, glass fibers, carbon fibers and wood fibers) as the main raw materials. The fibers are intertwined/entangled with each other. On the one hand, it can form an exhaust channel, which is conducive to air discharge and reduces the pores in the middle layer. On the other hand, the entangled fibers make the substrate have high internal bonding strength and excellent toughness. Not easy to crack. The base material prepared according to the above raw material ratio has the advantages of good toughness and high internal bonding strength.

Further, the length of the filler fibers is 3-200 mm.

By adopting the above technical scheme, each component is easier to disperse uniformly, and the obtained substrate has good dimensional stability and high internal bonding strength.

Further, the moisture content of the wood fiber is less than 8%.

By adopting the above technical scheme, the pores caused by the vaporization of water in the wood fiber are reduced, which is beneficial to improve the bonding strength in the base material and improve the anti-cracking performance of the base material.

Further, the filling fibers are mixed from PET fibers, PE fibers, glass fibers, carbon fibers and wood fibers in a mass ratio of 1:(0.5-1):(0.5-1):(0.5-1).

The overall performance of the base material prepared by adding the above-mentioned filling fibers is better.

Further, the wood fiber is pine fiber, hemp fiber, poplar fiber, basswood fiber, birch fiber, ash fiber, beech fiber, color wood maple fiber, eucalyptus fiber, fir fiber, cedar fiber, oak fiber , a mixture of one or more of camphor wood fiber and bamboo fiber.

The above-mentioned various wood fibers have the advantages of being renewable and easy to obtain, which makes the solution of the present application easy to realize.

Further, the flame retardant is a halogen-free flame retardant.

By adopting the above technical solution, the substrate has good flame retardant performance, and is more environmentally friendly than halogen-containing flame retardants.

Further, the flame retardant is magnesium hydroxide, aluminum hydroxide or a mixture of the two.

By adopting the above technical solution, not only can the substrate have good flame retardancy, but also some magnesium hydroxide and aluminum hydroxide are decomposed by heat during the hot pressing process of the substrate to release bound water, absorb a large amount of latent heat, and reduce polypropylene The pyrolysis of the molecular chains of fibers, PET fibers and PE fibers during the hot pressing process is beneficial to improve the strength of the substrate.

Further, the inorganic filler is calcium carbonate, fly ash, bentonite or clay.

By adopting the above technical solution, the dimensional stability of the base material is improved, so that the base material is not easy to shrink and deform. When calcium carbonate is added as an inorganic filler, it can decompose and release carbon dioxide under high temperature conditions, and also has the effect of improving the flame retardant performance of the substrate in synergy with the flame retardant.

A preparation method of a composite board base material, comprising the following steps:

Step 1, mixing inorganic filler, filler fiber and coupling agent to obtain mixed filler;

Step 2, blending the mixed filler with polypropylene fibers to obtain a blend;

Step 3: paving the blended material into a strip shape and then pressing and forming, and then cutting it into a sheet shape to obtain a tablet;

Step 4: After stacking the multi-layer webs, hot-press for 5-30min at a temperature of 165-250°C and a pressure of 5-20MPa, and cool to obtain a semi-finished product of the base material;

Step 5. Trimming the semi-finished product of the base material, and sanding it into a finished base material.

By adopting the above technical solution, the inorganic filler, filler fiber, coupling agent and polypropylene fiber are mixed step by step, and then pressed into a sheet-like material, at this time, a flat mesh has been initially formed by the polypropylene fiber and the filler fiber. After that, the multi-layer sheet materials are stacked, and the fiber materials also form a spatial three-dimensional network structure, which retains enough exhaust channels, and the fibers are entangled with each other. The semi-finished base material is obtained by bonding, shaping and cooling, and finally the finished base material is obtained by trimming and sanding. The obtained base material has the advantages of good dimensional stability and high tenon-groove strength. During the processing, the thickness of the sheet is controlled in the range of 1-20mm, which can be selected according to the actual processed products.

A decorative board, comprising a base material and a decorative layer, the base material is made by hot pressing of the following raw materials by mass percentage,

The filling fiber is a mixture of one or more of PET fiber, PE fiber, glass fiber, carbon fiber and wood fiber; the decorative layer is a melamine-dipped paper layer, an HPL layer or a PP decorative surface layer.

By adopting the above technical scheme, the decorative board has high dimensional stability, good flexibility and high internal bonding strength, and it is not easy to cause the decorative board to be cracked and scrapped when the edge of the decorative board is opened with a groove or milled out of a buckle. Among them, melamine impregnated paper layer, also known as melamine paper, has good water resistance; HPL (High-pressure Laminate), also known as thermosetting resin impregnated paper high pressure laminate, has good fire resistance, rich colors and textures; PP decoration The surface layer can be PP transparent material, PP printing film, etc. The decorative surface layer in this application can be selected according to actual needs, and decorative boards with different decorative effects or styles can be obtained.

To sum up, the present application includes at least one of the following beneficial technical effects:

1. Compared with the traditional glass magnesium board base material, the base material of this application does not need to use magnesium oxysulfide gel material, so there is no problem of moisture absorption and halogen return; at the same time, the composite board base material of this application is made of polypropylene fiber. and filling fiber (the filling fiber is a mixture of one or more of PET fiber, PE fiber, glass fiber, carbon fiber and wood fiber) as the main raw material and is made by hot pressing, and the fibers are interlaced/entangled with each other. The formation of exhaust channels is conducive to air discharge and reduces the pores in the middle layer. On the other hand, the entangled fibers make the substrate have a high internal bonding strength and are not easy to crack;

2. In the preparation method of the base material of the present application, the inorganic filler, filler fiber, coupling agent and polypropylene fiber are mixed step by step, and then pressed into a sheet-like material. At this time, the plane formed by the polypropylene fiber and the filler fiber has been initially formed. After that, the multi-layer sheet material is laminated, and the fiber material also forms a spatial three-dimensional network structure to retain enough exhaust channels. At the same time, the fibers are entangled with each other. After hot pressing, the air can be quickly exhausted to reduce the pores and make the fibers The materials are bonded to each other and shaped, cooled to obtain the semi-finished base material, and finally the finished base material is obtained by trimming and sanding. The obtained base material has the advantages of good dimensional stability, good flexibility and high internal bonding strength;

3. Select the melamine-dipped paper layer, HPL layer or PP decorative surface layer as the decorative surface layer and the decorative board obtained by compounding the substrate disclosed in this application not only has good decorative effect, but also has good dimensional stability, good flexibility and internal bonding. The advantage of high strength.

detailed description

Examples 1-6:

Examples 1-6 all relate to a composite board base material, which is made from the raw materials in the proportions shown in Table 1 through hot pressing.

Table 1. Raw material ratio table of embodiment 1-6

Among them, the specifications of polypropylene fibers and filler fibers are shown in Table 2-1, and the proportion of filler fibers is shown in Table 2-2. Calcium carbonate can also be replaced by other inorganic mineral fillers such as fly ash, bentonite, and clay.

Table 2-1. Example 1-6 fiber specification and composition table

Table 2-2. Composition ratio table of filled fibers in Examples 1-6 (by weight)

Among them, wood fibers are selected from pine fibers, hemp fibers, poplar fibers, basswood fibers, birch fibers, ash fibers, beech fibers, maple fibers, eucalyptus fibers, fir fibers, and cypress fibers with a moisture content of less than 8%. , tussah fiber, camphor fiber, bamboo fiber in one or more of the mixtures can be, embodiment 4 and embodiment 6 selected are all bamboo fiber.

The magnesium hydroxide, aluminum hydroxide, titanate coupling agent, silane coupling agent and calcium carbonate used in Examples 1-6 were all purchased through commercial channels, and the specific specifications are shown in Table 3.

Table 3. Example 1-6 raw material specification information table

raw material Specification magnesium hydroxide 95% pure Aluminum hydroxide 99% pure Titanate Coupling Agent Industrial grade A silane coupling agent 99% pure calcium carbonate Purity: AR, 99%

The preparation methods of Examples 1-6 are basically the same, and the only difference is that the process parameters of the hot pressing step are different.

The preparation process steps of the composite board substrate are as follows:

Step 1. Weigh each raw material according to the proportioning in Table 1, first mix the weighed calcium carbonate, filler fiber and coupling agent to obtain mixed filler;

Step 2, blending the mixed filler with polypropylene fibers to obtain a blend;

Step 3: After paving the blended material into a strip shape, press it with a calendering roller, and then cut it into a sheet shape to obtain a tablet;

Step 4: After stacking the multi-layer material sheets, enter the hot press for 5-30min under the conditions of temperature 165-250°C and pressure 5-20MPa, and cool to obtain semi-finished base material;

Step 5. Trimming the semi-finished product of the base material, and sanding it into a finished base material.

Table 4 shows the hot pressing process parameters of the preparation process of the composite board base material in Examples 1-6.

Table 4. Example 1-6 hot pressing process parameter table

Hot pressing process parameters Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Hot pressing temperature/℃ 165 195 220 250 200 180 Hot pressing pressure/MPa 20 15 10 5 13 12.5 Hot pressing time/min 5 13.5 18 30 15 17.5

Examples 7-12:

Examples 7-12 are all based on Example 6, and differ from Example 6 only in that the composition of the filling fibers is different. Table 5 shows the composition of the filled fibers in specific examples 7-12.

Table 5. Filled fiber composition table in Examples 7-12

Example 13:

Weigh each raw material according to the ratio of Example 6, directly mix each raw material, then spread it into a mold, press with a hot press for 17.5 min at 180 ° C and 12.5 MPa pressure, cool down and demould to obtain a semi-finished product of the substrate , and then trimming and sanding to obtain the finished substrate.

Comparative Example 1:

The only difference from Example 6 is that the filler fibers are replaced by the same amount of polypropylene fibers.

Comparative Example 2:

The only difference from Example 6 is that the calcium carbonate is replaced by the same amount of polypropylene fibers.

Comparative Example 3:

The difference from Example 6 is that the blending amount of polypropylene fibers is 50%, the blending amount of filler fibers is 40%, and the blending amounts of other components are unchanged.

Performance Testing

A. With reference to GB/T17657-2013, the internal bonding strength and static bending strength of Example 1-13 and Comparative Example 1-3 were determined, and the test results were recorded as shown in Table 6.

B. Flexibility test

A sample with a width of 5mm is wound on a φ4mm polished round bar continuously and tightly for 10 turns at a speed of 1r/s. The tension on the sample during winding is just enough to make the sample contact the round bar. Avoid testing during winding. The sample is stretched and twisted. After winding, use a 6x magnifying glass to check whether the sample is cracked, repeat the test ≥ 10 times, and count the proportion of cracked samples (crack rate).

Table 6. Test results of internal bond strength and flexibility (sample thickness 5mm)

sample Internal bond strength/MPa Static bending strength/MPa Cracking rate/% Example 1 3.8 32 0 Example 2 4.0 33 0 Example 3 4.2 35 0 Example 4 4.3 33 0 Example 5 3.9 32 0 Example 6 4.4 36 0 Example 7 4.2 34 0 Example 8 4.3 35 0 Example 9 4.3 35 0 Example 10 4.3 35 0 Example 11 4.2 33 0 Example 12 4.0 32 0 Example 13 4.3 34 0 Comparative Example 1 3.4 26 1.2 Comparative Example 2 3.2 28 0.7 Comparative Example 3 3.7 30 0.2

It can be seen from the test data in Table 6 that the internal bonding strength of the substrate of the present application is as high as 3.8-4.4MPa, and the static bending strength is as high as 32-36MPa, which has the characteristics of good strength. At the same time, the base material of the present application can be wound on a 4mm diameter round rod for 10 turns without visible cracking, and has excellent flexibility. In addition, by comparing the test data of Example 6 and Comparative Examples 1-3, it can be found that the bonding strength is higher and the flexibility is excellent in the substrate of the specific ratio of the present application.

C. With reference to GB/T17657-2013, the water absorption thickness swelling ratio of the substrates of Example 1-13 and Comparative Example 1-3 was determined, and the test results were recorded as shown in Table 7.

D. Test the dimensional change rates of the substrates of Examples 1-13 and Comparative Examples 1-3 under different temperature environments, respectively. The size measurement method refers to GB/T17657-2013, the initial size of the sample is 50*50*5 (25°C), and the sample is placed at -20°C and 80°C for 6 hours, and the size is measured immediately after the calculation. The rate of change between initial dimensions. The average of the absolute values of the rate of dimensional change of at least three measurements was recorded to represent the dimensional stability of the specimen. The test results are recorded in Table 7.

Table 7. Test results of absorption thickness expansion ratio and dimensional stability (sample thickness 5mm)

From the test data in Table 6, it can be seen that the water absorption thickness expansion rate of the substrate of the present application is as low as 0.08-0.10%, the dimensional change rate at 80°C is as low as 0.02-0.03%, and the dimensional change rate at -20°C is as low as 0.01-0.02%. Excellent moisture dimensional stability and high and low temperature dimensional stability. In addition, by comparing the test data of Example 6 and Comparative Examples 1-3, it can be found that the moisture resistance dimensional stability and the high and low temperature resistance dimensional stability of the substrate in the specific ratio of the present application are better.

Application example 14-16:

Application Examples 14-16 all relate to a decorative board, which is based on the composite board substrate of Example 6, and includes a decorative layer, a non-woven layer, a substrate, a non-woven layer and a balance layer that are sequentially compounded. After laying each layer of material on the mold in sequence, it enters the hot press for 50-1800s under the conditions of 180-250℃ and 8-20MPa pressure. Snaps can be milled out on the edge of the trim panel as required. The decorative layer can be selected from melamine wear-resistant paper or melamine patterned paper impregnated with melamine-formaldehyde. In application examples 14-16, melamine patterned paper is selected; both non-woven layers are PP non-woven fabrics; balance layer The choice is melamine wear-resistant paper; the base material used is the composite board base material of Example 6.

The hot pressing process parameters of Application Examples 14-16 are shown in Table 8.

Table 8. Application example 14-16 hot pressing process parameter table

Hot pressing process parameters Application example 14 Application example 15 Application example 16 Hot pressing temperature/℃ 180 215 250 Hot pressing pressure/MPa 20 14 8 Hot pressing time/s 50 1200 1800

Application example 17-19:

Application examples 17-19 all relate to a decorative board, which includes a base material and an HPL layer, and the base material and the HPL layer are formed by cold pressing two-component PU glue or PUR glue. Among them, the substrates selected are all the composite board substrates of Example 6, the application examples 17-18 are all compounded by PU glue, and the application example 19 is compounded by PUR glue.

Preparation Process:

First, melamine wear-resistant paper, melamine patterned paper, non-woven fabric or kraft paper impregnated with phenolic glue is made into HPL by high-temperature hot pressing at 130-180℃ and 10-20MPa for 15-90min; then, HPL is used with the substrate Two-component PU glue or PUR glue is cold-pressed and compounded, and the compounding pressure is 5-20MPa; after the glue is completely cured, the semi-finished product is obtained, and the decorative board is obtained by cutting and trimming. Snaps can be milled out on the edge of the trim panel as required.

The HPL preparation process parameters and composite pressure parameters of Application Examples 17-19 are shown in Table 9.

Table 9. HPL preparation process parameters and composite pressure parameters

Application example 20-22:

Application examples 20-22 all relate to a decorative board, comprising a PP transparent material layer, a PP printing film layer and a base material layer arranged in sequence, wherein the base material layer is the composite board base material of Example 6.

Preparation Process:

Lay the PP transparent material, PP printing film, and base material on the mold, and then use a hot-pressing machine for one-time composite molding. After cooling and shaping, take it out, maintain it to room temperature, temper at 70-99°C, cool it to obtain a semi-finished product, and then cut and trim the edges to obtain the finished decorative board. Snaps can be milled out on the edge of the trim panel as required.

The hot pressing process parameters of Application Examples 20-22 are shown in Table 10.

Table 10. Hot pressing process parameter table of application examples 20-22

Hot pressing process parameters Application example 20 Application example 21 Application example 22 Hot pressing temperature/℃ 180 215 250 Hot pressing pressure/MPa 20 14 10 Hot pressing time/min 15 30 60

The above-mentioned embodiment is only an explanation of the application, and it is not a limitation to the application. Those skilled in the art can make modifications without creative contribution to the above-mentioned embodiments as needed after reading this specification, but as long as the right of the application is used. All claims are protected by patent law.

Claims (10)

A composite board base material, characterized in that: it is made by hot pressing of the following raw materials by mass percentage,

The filler fiber is a mixture of one or more of PET fiber, PE fiber, glass fiber, carbon fiber and wood fiber. The composite board substrate according to claim 1, wherein the length of the filler fibers is 3-200 mm. The composite board base material according to claim 2, characterized in that: the moisture content of the wood fiber is less than 8%. The composite board substrate according to claim 3, characterized in that: the filling fibers are composed of PET fibers, PE fibers, glass fibers, carbon fibers and wood fibers in a mass ratio of 1:(0.5-1):(0.5-1) : (0.5-1) mixed. The composite board substrate according to claim 4, characterized in that: the wood fiber is pine fiber, hemp fiber, poplar fiber, basswood fiber, birch fiber, ash fiber, beech fiber, color wood maple fiber , a mixture of one or more of eucalyptus fiber, fir fiber, cedar fiber, oak fiber, camphor fiber and bamboo fiber. The composite board substrate according to claim 1, wherein the flame retardant is a halogen-free flame retardant. The composite board substrate according to claim 6, wherein the flame retardant is magnesium hydroxide, aluminum hydroxide or a mixture of the two. The composite board substrate according to claim 1, wherein the inorganic filler is calcium carbonate, fly ash, bentonite or clay. The preparation method of the composite board base material according to claim 1, is characterized in that: comprises the following steps: Step 1, mixing inorganic filler, filler fiber and coupling agent to obtain mixed filler; Step 2, blending the mixed filler with polypropylene fibers to obtain a blend; Step 3: Paving the blended material into a strip shape and then press molding, and then cut into a sheet shape to obtain a tablet; Step 4: After stacking the multi-layer webs, hot-press for 5-30min at a temperature of 165-250°C and a pressure of 5-20MPa, and cool to obtain a semi-finished product of the base material; Step 5. Trimming the semi-finished product of the base material, and sanding it into a finished base material. A decorative board, comprising a base material and a decorative layer, characterized in that: the base material is the composite board base material according to claim 1; the decorative layer is a melamine-dipped paper layer, an HPL layer or a PP decorative surface layer .